Conclusions: The new findings have several important implications for GSI dose
reconstructions and revision of Appendix BB Rev 0 to TBD-6000, as follows:

1. Radiographic NDT work with the General Steel Castings (company name
changed to General Stee! Industries in 1961) on MCW uranium ingots had already
begun in November and December 1952.

2. Based on conclusion #1, the operational period at GS] should be changed to
start on November 1, 1952, instead of the current start date as January 1, 1953.

ay: NIOSH should coordinate these new GSI data with both U.S. DOE and U.S. DOL
offices that deal with EEOICPA matters (DCAS, DEEOIC).

4. The new work described was a collaboration between AEC Oak Ridge,
Mallinckrodt Chemical Works, Allis Chalmers, and General Steel Castings (aka GSI).
The Hanford Data Capture site may have been part of this collaboration.

5. The November and December 1952 GSI Betatron work is not confirmed by
any yet discovered MCW purchase orders or contract or contract letter between
MCW and GSI. However, the new information implies that such documents probably
did exist, and renewed efforts should be made to obtain them from U.S. DOE.

6. The described 1” ingot slices differ from other MCW uranium source terms
used at GSI for dose reconstructions and SEC analyses. This new uranium source
term is not characterized as to total weight, or number of ingots examined in 1952.

7. The new information clearly indicates that the GSI Allis Chalmers Old
Betatron x-ray unit was installed and doing U.S. government work during 1952. It is
not yet clear when the first MCW uranium came on site at GSI, and if that date was
earlier than November 1, 1952.

8. Anew shield, or shields, made by MCW to collimate the Betatron beam is
described that has not been recognized or used in existing NIOSH and SC&A models
of Old Betatron operations at GSI 1953-1966. Additional efforts should be made to
locate such records at Oak Ridge ORO. Appendix BB Rev 0 should be revised.

Respectfully submitted,

Daniel McKeel, Jy., M.D. November 17,2012
GSI SEC-00105 co-petitioner



sey

and §" ingots poured with a riser witn Fibrefrax around the riser are the most
Promising developments to date in the aliminstion of centerline defects,

Popresentatives of the Allis Chelmers’ Company have been working with
MCW and with personnel of General Steel Castings Company on the use of
Betatron for x-raying uranium. In connection with x-raying of 1" sections
Good progress has Leen made in reducing the required exposure time end also
in obtaining mors definitive negatives. The uranium shield which was cast
for use in the x-raying of whole ingots has been modified to permit a decrease
in exposure time. A single picture has deen taken of a 1/8" section by a
technique permitting u maynificution 22%1/2 tines vormal7Toe Slice was taken
from a section of ingot which uad previously had 2 1” longi fnesinel section
removed. So cuvities either micro or macro were observed. Pee

%
a
Se)

%

experiments nlong this ling will be made.

Visitors

Kessrs. Walter ll. beal, Jre, George 3, Sheldon, dr., ueorga Re Folin,
and Edward F, Shaffsr of the Special Staff of the House Committee on
Appropriations visited the $+. Louis Area on December 12, 1952.

2. Feed Katerials Froduction Center

Metallurgical Departwent

Beta heat treatment on the Hanford order for heat treated bars (8l ton ¥
balance) has been postponed at the request of Hanford Works until the week follow
ing the January rolling st Sinonds x now scheduled to start Jarmary 19, 1953.

Work will be resumed on the 0.9% NAA order upon completion of the writing
SFA vevleed: seanand ‘cpereting: procedinpy

The machining of Hanford 1.75 & emféyhed rods has been delayed in ordar
to obtsin approved operating procedures. Ma will be resumed as soon as
these procedures are epproved, now scheduled cobb yecdary 2-L,1953.

, “
ee <,


7 oa

— DATA CAPTURE DOCUMENT | ORAU TEAM
wes Wy | DISCOVERY AND REVIEW | pacers most”

The attached document may contain Privacy Act data. This information is protected by the Privacy Act, 5 U.S.C. §552a;
disclosure to any third party without written consent of the individual to whom the Information pertains is strictly prohibited.

Data Capture Team or Other ORAU Team Member Capturis

turing Data: Complete all information that applies to the data/document being
submitted for uploading to the Site Research Database (SRDB), attach this form to the front of the document, and send to; ORAU
Team, Attention: SRDB Uploading, 4850 Smith Rd., Suite 200, Cincinnati, Ohio 45212.

x SAPs ea ge Requestor and Reviewer — ea a Tyee ae
4. Data Requestor, Tim Taulbee
2. Reviewer Name (if different from Requestor); Brant Ulsh
3, Target Data: Thorium information from AWE sites
4. Dale Collected: 4/5/2011 - 4/8/2011
~ ys Source Information Captured Database Information.
5. Site of Capture: Oak Ridge Vault- RHTG 10. Database Name:
6. Site Box Number, O 11. Soltware/Hardware Requirements:
7, AccessionNumber: KHTG - 201%
8. Location (if nat located In box):
9. FolderTile: Welly, Repo . Metal Lergical Develeprratl Remeh i 19sfz-
ug Data/Document ; ‘ soy
12 Document Date: p2/y fp — 1 4/ Use 16. Document Type (check all that apply):
OO Facilities/Process
13. Document Number: (i.2., Source terms, contamination surveys, general
area/breathing-zone air sampling, area radiation
14, Reviewer Description (if needed) (€.9., keywords, Surveys, radon/thoron monitoring, fixed location
document comments, date ranges): dosimeters, missed dose information, radiological contro}
limits, radiation work permits, incidents/accidents)
0 Medical Monitoring
(Le. X-rays, occupational medical exams, exam
frequencies, equipment performance characteristics)
(1 Environmental Monitoring
(..@., ambient radiation, onsite releases, onsite
15. Sites to Which Document Applies (check all that apply): radionuclide concentrations)
A poe Sites pfu Fox (1 internat Dosimetry
N: R (i.e., urinalysis, fecal, in vivo, breath sampling,
fadon/thoron, nasal smears, analytical methods, sample
a AWE Sites (eenr-nl Stew { Gwe tow frequency, detection fimils, recordkeeping practices,
Names: Mea codes, performance characteristics)
External Dosimetry
Genera information a (Ce., thermoluminescent dosimeters, film badges, pocket
jon chambers, analytical methods, exchange frequency,
To Be Completed ’By Records Management coe
17. File Name (if electronic): Oo Individual/Group Data
18, Project Document Number; (.e., individual or group data)

DRAUT-FORM-0015 Rev 07, Effective 04/18/2008


AINO AASSAUAAGY Ad GANAdO Ad OL

SUAMYOM ADYANA UVATOAN SIONITH NYFHLIOS:

Ul“ TIANOW "MA TAINVG “UG





Dragon, Karen E. (CDC/NIOSHIEID)

From: Dan McKee! <

Sent: Monday, November 19, 2012 2:28 AM

To: Hinnefeld, Stuart L. (CDC/NIOSH/DCAS); Greg Lewis; James Melius; John Mauro; Paul
Ziemer, Katz, Ted (CDC/NIOSH/OD); NIOSH Docket Office (CDC)

Ce: Dan McKeel, ,

Subject: New GSI DOE ORO FOIA info; BETATRON MCW WORK 1952

Attachments: MCKEEL_New_FOIA_GSI-1952. pdf

Stuart Hinnefeld (DCAS Director)

Greg Lewis (DOE EEOICPA Program Manager
James Melius (Chair, ABRWH)

Paul Ziemer (Chair, TBD-6000 work group)
‘Ted Katz (DFO, ABRWH)

Karen Dragon NIOSH Docket 140 Office
November 18. 2012
Dear Mr. Hinnefeld, Greg Lewis, Drs. Melius and Ziemer, John Mauro, NIOSH Docket Office, and Ted Katz.

1 wish to bring to your urgent attention new information I have recently gleaned from the DOE Oak Ridge
FOIA Office response ORO-2013-00013-F that is pertinent toa FOIA request | made concerning MCW DOE
records and the General Steel Industries (GSI) (aka Granite City Castings) AWE site located in Granite City,
Illinois. The new information was discovered in Data Capture records requested by Tim Taulbee of ORAU and
reviewed by Brandt Ulsh April 4-8, 2011.

The attached PDF document incorporates the main new finding that GSI was actively cooperating with ORO,

Hanford, MCW, Allis Chalmers in performing Betatron nondestructive testing radiography on MCW

uranium ingots and ingot 1 inch slices as early as November and December 1952. Those dates are prior to
the start of the official GSI AEC operational period, which is currently January 1, 1953. These dates are prior to

having film badge data or AEC contracts or MCW purchase orders.

There is added information that MCW constructed and modified a shield or shields that GSI used on whole
MCW uranium ingots to collimate the 24 Mev GSI Allis Chalmers built and US Government owned
Betatron x-ray beam. That MCW uranium process fact was not known about prior to my receiving this new
FOIA information. The discovery may have some possibly important ramifications on existing NIOSH and
SC&A Betatron output modeling and dose reconstruction practices that will need to be incorporated into
revising Appendix BB Rev 0 to TBD-6000, The new information also may have an influence on the work group
and full Board recommendations on GSf SEC-00105.

Ted Katz, please circulate this e-mail to all members of the ABRWH. Thank you.

Karen Dragon, please consider posting this e-mail and the PDF attachment to NIOSH Docket 140 for GSI.
Thank you as weil.

Sincerely,

Daniel W. McKeel, Jr., M.D.


44 phigh, plazh ilivte cat eattpncdacktin bailete: have heed deatruas
tively axemined to determine the extent of axial cavities. During the early
part of the program the only technique availabie for this study consisted of
sawing billets down the center and photographing. During the past month tais
technique has been supplanted by the practice of making Betatron radiographs of
Ininch slices taken fron the centers of the ingots, cH Mag xpeeived consider
able assistance in the development of Betatron techniques frum the siié:?
Chalmers Corporation and The General Steel Castings Corporation. very effort
is now being made to develop a non-destructive test method using the Betatron.

In order to accomplish radiography on a 5~inch cylindrical section,
it 4s necessary to shield the section perpendicular to the direction of beam
incidence in order to eliminate scattering and secondary radiation effects,
Such a shield has been cast, and final machining and radiographic testing with
it will take place in the near future,

Evidence accumulated from destructive billet examination indicates that
macroporosity is largely limited to the central core of the billet and is the
result of intermittent freesing at various points along tie length of the billet.
‘ kocardingly, experimentation has been directed to obtaining directional freezing
of metal from the bottom to the top of tho billet. Very promising results have
been obtained through the use of large dimeter molds.

In an 8-inch diameter billet approximately 00 pounis of sound casting
has been produced from about 600 pounds of metal, his contrasts with about
80 pounds of sound metal at the bottom of the regular MOW production ingot.

Other techniques utilised to lidification include
externally-tapered graphite molds (the larger seotion at th bottom), neta)
reflectors placed around the mold, and insulating waterials in contect with the
upper portions of the mold, The best results thus far have been achieved with
® tapered mold utilising Fibrefrax insulation around the upper portion of the
mold. Thirty-three inches of almost perfectly sound metal were produced in s



MBE IO 7 14 F2Y
ALLE,

ee oy

Classificaon Changed to UNCLASSIFIED

” DAR-/
” “ Glassification Authority
o-To

Anatysas Corp, ———_ £
Zee Sal. git
OGE-GE Qa
Bt WL pe
MONTHLY REPORT ~ 8o,

OY, —
Som Fs a
ROVEMBER 1952, ad

480

As submitted to Dr. Slesser


s

siting rt onic 7
Office Memorandum * UNITED STATES GOVERNMENT
To : P.M. Belmore DATE: Necember 17, 1952

ne age RH oa

supyact: WEEKLY REPORT - Dec. 11-17, 1952
METALLURGICAL DEVELOPMENT BRANCH

‘T
a

ut,
H ae I. Thorium Pabrication Ono alae: nay €- ie
3 { : 3 ¢ Machining of 1300 thorium slugs (Hanford dimencions) for Oak Ridge
EH 2 r q Wational Laboratory's dissolution atudy tont in now completed und
2 & PS shipment will be made Docenver 19 or 22. This work completes ORNL's
Es > 5 3,000 slug lot requirement.
; 3 br 211 *Uranium Fabrication
= my 1. Derbi@us pickled in nitric ucid were melted and onst into three

experimental ingots. Nansitios at the tops und bottums of these

Re

ingots ranged betwoen 18.93 to 19.01,

2s
sé on 2. A third attemt to x-ray « 5" diameter ingot non-dostructively was
oz made at Ceneral Stee) Castings Co. using uraniur shields which wore
«
28 | cast at MGI. 4 1/8" diametor hole was detected with an exposure
ga z timo of $5 minutes which Sorresponds to 500 rosntgena at the

center of the x-ray bean, Additional tests will be made to refine
the above tochnique,

‘The oxperimental slug production rate at Gylvania's plant in

DATE.
#-
a

I4

Hicksville has now reached a Revel of 7 slugs por 8 hour day.

Axial compression tests made on cylinders cut from slugs show

ory

tho surface quelity of powder motallurgy slugs at Sylvania to be

greatly superior to that of rolled end machined slugs.

seu

CLASEINIC *TION


5. Stapled together are 15 pages labeled: RHTG - 13, 905, Box #44. “Monthly Report
Production Division, December, 1952. As submitted to Dr. Slesser." Page 6 of 15 has
a green margin flag,

[McKeel note: The second paragraph is the crucial new information]. The
text is as follows:

“Representatives of the Allis Chalmers Company have been working with
MCW and with personnel of General Steel Castings Company on the use of
Betatron for x-raying uranium. In connection with x-raying of 1” sections good
progress has been made in reducing the required exposure time and also in
obtaining more definitive negatives. The uranium shield which was cast for us
in the x-raying of whole ingots has been modified to permit a decrease in
exposure time. A single picture has been taken of a 1/8" section by a technique
permitting a magnification of 2 to 2 % times normal. The slice was taken from a
section of ingot which had previously had a 1” longitudinal section removed. No
cavities either micro or macro were observed. Additional experiments along
these lines will be made.”

“Visitors

Messrs. Walter H, Beal, Jr., George H. Sheldon, Jr., George R. Rolin [or
Bolin?), and Edward P. Shaffer of the Special Staff of the House Committee on
Appropriations visited the St. Louis area on December 12, 1952,”

A copy of page 6 of this part of the ORO FOIA is MCKEEL EXHIBIT 2.

6. Stapled together are 18 pages labeled: RHTG - 13, 904, File Box #44, “Monthly
Report, November, 1952. As submitted to Dr. Slesser.” Page 7 of 15 has a green
margin flag,

{McKeel note: The first and second paragraphs are more of the crucial
new information]. The text is as follows:

“All pilot plant billets and many production billets have been
destructively examined to determine the extent of axial cavities, During the
early part of the program the only technique available for this study consisted of
sawing billets down the center and photographing. During the past month this
technique has been supplanted by the practice of making Betatron radiographs
of 1-inch slices taken from the centers of the ingots. MCW has received
considerable assistance in the development of Betatron techniques from the
Allis Chalmers Corporation and the General Steel Castings Corporation. Every
effort is now being made to develop a non-destructive test method using the
Betatron.

In order to accomplish radiography on a 5-inch cylindrical section, it is
necessary to shield the section perpendicular to the direction of beam incidence
in order to eliminate scattering and secondary radiation effects, Such a shield
has been cast, and final machining and radiographic testing with it will take
place in the near future.”

A copy of page 6 of this part of the ORO FOIA is MCKEEL EXHIBIT 3.

Attachments: Page 1 (envelope), pp 2-3 (Exhibit 1), pp 4-5 (Exhibit 2), pp (exhibit 3)


2. A single page, which is a more current facility description, probably part of a DOE
document, of "General Steel Industries” and several attachment pages that provide
details of the covered and residual periods at GSI. The first line on this page is
“Facility Description: Fermi National Accelerator Laboratory...” and page 45 is at the
lower right of the page. The last site entry is for Great Lakes Carbon Corp. General
Steel Industries is listed among 5 aka site names,

Time Period: AWE 1953-1966; Residual Radiation 1967-1992; DOE 1993
(remediation).

3. Five pages numbered 1-5 at bottom and a date 10/23/2002 at the lower right of
each page, that are labeled at top “FUSRAP Considered Site Name Crosswalk.” On
page 1, 4" entry is “IL-28 (column 1) and Granite City Steel” (column 2). The rest of
page 1 and pages 2-5 are other sites than GSI/Granite City Steel.

The Crucial New GSI Information
4. Stapled together are a cover page and three following pages (“Item 4”).

The cover page is identified as an “ORAU TEAM Dose Reconstruction Project for
NIOSH.” Date Collected: 4/5/2011-4/8/2011. Target data was: Thorium
information from AWE sites. Data requester was Tim Taulbee and Reviewer name
was Brandt Ulsh. Source Information, site of capture was: Oak Ridge Vault - RHTG,
Site Box number 90, Folder title: Weekly Report: Metallurgical Development Branch:
1952-12-11. Document date: 12/11/52 - 12/17/52.

The next page, one of three, (of item 4) with a green margin flag by item 2, was
marked as follows:

OFFICE MEMORANDUM « UNITED STATES GOVERNMENT, To: F.M. Belmore, From:
G.E. Dunlap, Date: December 17, 1952, Subject: is “WEEKLY REPORT - Dec. 11-17,
1952, METALLURGICAL DEVELOPMENT BRANCH.

¢ ITEM [is “Thorium Fabrication.” (refer to Exhibit 1 for more details)

* ITEM 2 is Uranium Fabrication as follows;

1. Derbies pickled...

2. [McKeel note: This is the crucial new information]; “A third attempt to
x-ray a 5" diameter ingot non-destructively was made at General Steel Castings
Co, using uranium shields which were cast at MCW. A 1/8” diameter hole was
detected with an exposure time of 35 minutes which corresponds to 4500
roentgens at the center of the x-ray beam. Additional test will be made to refine
the above technique.”

3. The experimental... [more text, not shown]

4. Axial compression tests... [more text, not shown]

A copy is attached to this part of ORO 2012-00013-F FOIA as MCKEEL EXHIBIT 1.


Daniel W. McKeel, Jr,, M.D.
GSI SEC-00105 Co-petitioner

DOE ORO_2013-00013-F FOIA
New information on GSI 24 Mev Betatron X-Ray Unit:
Non-Destructive Testing of MCW Uranium Ingots
Performed During November-December 1952

(version 1.0, 11/17/12)

Part 1. New DOE-ORO FOIA information concerning General Steel
Castings (aka General Steel Industries MCW-AEC uranium and
Betatron operations occurring in November and December 1952.
[DOE Oak Ridge Office FOIA ORO-2013-00013-F] NIOSH Docket 140

Office (“ORO")(Amy Rothrock) has been received and reviewed. The letter is dated
October 9, 2012, and is responding to a new FOIA request GSI SEC co-petitioner
Daniel McKeel submitted to the U.S. Department of Energy ("DOE") relating to
additional records at MCW-Destrehan Street or at the Weldon Spring site, that are
referable to the GS] site in Granite City, IL.

Background. The final response (FOIA: ORO-2013-00013-F) from DOE Oak Ridge

The new information proves the following:

(a) An active collaboration existed between the DOE Hanford site, the AEC,
Allis-Chalmers, MCW-Destrehan Street Uranium Division, and GSI to use its Betatron
nondestructive testing X-ray at least as early as November and December 1952.
Those dates both precede the current start of the DOE operational period for GSI;

(b) Different uranium forms (shape and sizes) were used in this 1952 work
from any others described to date in the MCW-AEC-GSI NDT collaboration;

(c) A metal shield (or shields) was built at MCW in 1952 to collimate the GSI
Betatron beam to produce superior x-ray radiographs of whole uranium ingots;

(d) There was direct collaboration between GSI-MCW and Hanford works in
1952, a fact not realized before this material emerged.

Besides the cover letter, the ORO FOIA response included five main documents, as
follows:

1. A single sheet with an outdated site description of GSI from a previous NIOSH
residual contamination report; “Appendix A-3 Residual Radioactivity Evaluation
for Individual Facilities, page 98 of 259." Time Period: 1958-1966; DOE 1993-
1994. The Facility Name is stated to be “Granite City Steel,” The Also Known As list
does not include General Stee! Industries, which is not mentioned anywhere on this
sheet (Note: Both dates are not the current ones for the covered operational and
residual periods).


Dragon, Karen E. (CDC/NIOSHIEID)

From: Dragon, Karen E. (COC/NIOSH/EID)

Sent: Monday, November 19, 2012 7:42 AM

To: Ellison, Chris (CODC/NIOSH/OD)

Cc: Leary, Glenda (COC/NIOSH/DCAS); Dragon, Karen E. (CDC/NIOSH/EID)
Subject: McKee! submissions - Docket 140

Chris — Here are 2 submissions from McKeel that have been redacted. One is an addendum. Thanks,
Karen

fq

0140-111012-Me.., 0140-111012-Mc,.

Karen E. Dragon | Docket Office Specialist | NIOSH Docket Office | 4676 Columbia Parkway, C-34 | Cincinnati, OH 45226 | v:(513) 533-8303
| f: (513) 533-8285